SCR catalyst ammonia surface coverage estimation and control

• US 9,475,006 B2
• Filed: 05/27/2014
• Issued: 10/25/2016
• Est. Priority Date: 04/26/2010
• Status: Active Grant

• Current Assignee: Cummins Filtration IP Inc. (Cummins Incorporated)
• Original Assignee: Cummins Filtration IP Inc. (Cummins Incorporated)
• Inventors: Ofoli, Abdul R., Mohammed, Hasan
• Primary Examiner(s): Bomberg, Kenneth
• Assistant Examiner(s): AYALA DELGADO, ANTHONY
• Application Number:
  US14/287,759
• Publication Number:
  US 20140314645A1
• Time in Patent Office: 882 Days
• Field of Search: 602/86, 602/97, 602/73, 602/76, 602/99, 423/212
• US Class Current: 1/1
• CPC Class Codes: B01D 2251/2062 Ammonia
• CPC Class Codes: B01D 2251/2067 Urea
• CPC Class Codes: B01D 2251/208 Hydrocarbons
• CPC Class Codes: B01D 2255/20723 Vanadium
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/911 NH3-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/90 Injecting reactants
• CPC Class Codes: B01D 53/9431 Processes characterised by a specific device
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2570/18 Ammonia
• CPC Class Codes: F01N 2900/0411 using a feed-forward control
• CPC Class Codes: F01N 2900/0412 using pre-calibrated maps, tables or charts
• CPC Class Codes: F01N 2900/0418 using integration or an accumulated value within an elapsed period
• CPC Class Codes: F01N 2900/1402 Exhaust gas composition
• CPC Class Codes: F01N 2900/1411 Exhaust gas flow rate, e.g. mass flow rate or volumetric flow rate
• CPC Class Codes: F01N 2900/1602 : Temperature of exhaust gas apparatus
• CPC Class Codes: F01N 2900/1616 : NH3-slip from catalyst
• CPC Class Codes: F01N 2900/1622 : Catalyst reducing agent absorption capacity or consumption amount
• CPC Class Codes: F01N 3/035 : with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/208 : Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Described herein are various embodiments of an apparatus, a system, and a methods for reducing NO_x emissions using ammonia storage on an SCR catalyst. For example, according to one embodiment, an apparatus for controlling an SCR system of an internal combustion engine system includes an ammonia storage module and a reductant dosing module. The ammonia storage module determines an ammonia storage surface coverage on an SCR catalyst of the SCR system and an ammonia compensation value based on one of an excess ammonia flow rate entering the SCR catalyst and an excess NO_x flow rate entering the SCR catalyst. The reductant dosing module that generates a reductant dosing command based on the ammonia compensation value.

Claims

1. A controller for controlling a selective catalytic reduction (SCR) system of an internal combustion engine system comprising:

a reductant dosing module configured to generate a reductant command based, at least in part, on a determined ammonia compensation value and output the generated reductant command to a reductant delivery system, the reductant delivery system injecting reductant into an exhaust gas stream at a rate based on the generated reductant command; and

an ammonia storage module comprising;

a mode determination module configured to determine an operating mode of the SCR system as one of an adsorption mode, a desorption mode, or a neutral mode;

an ammonia adsorption mode module or an ammonia desorption mode module configured to receive a first ammonia storage surface coverage value and calculate a second ammonia storage surface coverage value based, at least in part, on the determined operating mode of the SCR system; and

an ammonia storage control module configured to determine the ammonia compensation value based, at least in part, on the calculated second ammonia storage surface coverage value and output the determined ammonia compensation value to the reductant dosing module.

2. The controller of claim 1, wherein determining the mode determination module is configured to determine the operating mode of the SCR system based, at least in part, on a SCR catalyst temperature and an ammonia-to-NO_x ratio upstream of a SCR catalyst.

3. The controller of claim 2, wherein determining the mode determination module is configured to determine the operating mode of the SCR system as one of the adsorption mode, the desorption mode, or the neutral mode based on comparing the ammonia-to-NOx ratio upstream of the SCR catalyst to a zero slip threshold of an ammonia storage table for the SCR catalyst temperature.

4. The controller of claim 2 wherein the ammonia storage module further comprises:

an excess ammonia flow rate module configured to determine an excess ammonia flow rate responsive to the mode determination module determining the operating mode of the SCR system is the adsorption mode;

wherein the ammonia adsorption mode module calculates the second ammonia storage surface coverage value based, at least in part, on the determined excess ammonia flow rate.

5. The controller of claim 4, wherein the ammonia adsorption mode module calculates the second ammonia storage surface coverage value based, at least in part, on a time constant from an adsorption ammonia storage table for the determined excess ammonia flow rate and a SCR catalyst temperature.

6. The controller of claim 5, wherein the time constant corresponds to a predetermined rate of increase of ammonia storage surface coverage of a SCR catalyst.

7. The controller of claim 2 wherein the ammonia storage module further comprises:

an excess NO_x flow rate module configured to determine an excess NO_x flow rate responsive to the mode determination module determining the operating mode of the SCR system is the desorption mode;

wherein the ammonia desorption mode module calculates the second ammonia storage surface coverage value is based, at least in part, on the determined excess NO_x flow rate.

8. The controller of claim 7, wherein the ammonia desorption mode module calculates the second ammonia storage surface coverage value based, at least in part, on a time constant from a desorption ammonia storage table for the determined excess NO_x flow rate and a SCR catalyst temperature.

9. The controller of claim 8, wherein the time constant corresponds to a predetermined rate of decrease of ammonia storage surface coverage of a SCR catalyst.

10. The controller of claim 2, wherein the ammonia storage module is configured to set the first ammonia storage surface coverage value to zero responsive to a high temperature event.

11. A system comprising:

an SCR system including;

a reductant delivery system, and

an SCR catalyst, and

a controller configured to;

receive a first ammonia storage surface coverage value indicative of an amount of ammonia stored on a surface of the SCR catalyst,

determine an operating mode of the SCR system as one of an adsorption mode, a desorption mode, or a neutral mode,

calculate a second ammonia storage surface coverage value based, at least in part, on the determined operating mode of the SCR system,

determine an ammonia compensation value based, at least in part, on the calculated second ammonia storage surface coverage value,

generate a reductant command based, at least in part, on the determined ammonia compensation value, and

output the generated reductant command to the reductant delivery system.

12. The system of claim 11, wherein determining the operating mode of the SCR system is based, at least in part, on a temperature of the SCR catalyst and an ammonia-to-NOx ratio upstream of the SCR catalyst.

13. The system of claim 12, wherein the ammonia-to-NOx ratio upstream is based, at least in part, on an amount of NOx determined from an engine calibration table.

14. The system of claim 13, wherein the ammonia-to-NOx ratio upstream is based, at least in part, on an amount of NOx received from a NOx sensor upstream of the SCR catalyst.

15. The system of claim 13, wherein the ammonia-to-NOx ratio upstream is based, at least in part, on an amount of ammonia dosed by the reductant delivery system.

16. The system of claim 13, wherein the ammonia-to-NOx ratio upstream is based, at least in part, on an amount of ammonia received from an ammonia sensor upstream of the SCR catalyst.

17. A method comprising:

setting a first ammonia storage surface coverage value to zero responsive to a high temperature event;

determining an operating mode of an SCR system;

calculating a second ammonia storage surface coverage value based, at least in part, on the determined operating mode of the SCR system;

determining an ammonia compensation value based, at least in part, on the calculated second ammonia storage surface coverage value;

generating a reductant command based, at least in part, on the determined ammonia compensation value; and

outputting the generated reductant command to a reductant delivery system, the reductant delivery system injecting reductant into an exhaust gas stream at a rate based on the generated reductant command.

18. The method of claim 17, wherein the determined operating mode of the SCR system is one of an adsorption mode or a desorption mode.

19. A non-transitory computer-readable memory device storing instructions that, when executed by one or more processors, cause the one or more processors to perform operations comprising:

interpreting a first ammonia storage surface coverage value;

determining an operating mode of an SCR system as one of an adsorption mode, a desorption mode, or a neutral mode;

calculating a second ammonia storage surface coverage value based, at least in part, on the determined operating mode of the SCR system;

determining an ammonia compensation value based, at least in part, on the calculated second ammonia storage surface coverage value;

generating a reductant command based, at least in part, on the determined ammonia compensation value; and

outputting the generated reductant command to a reductant delivery system, the reductant delivery system injecting reductant into an exhaust gas stream at a rate based on the generated reductant command.

20. The non-transitory computer-readable memory device of claim 19 storing instructions that cause the one or more processors to perform operations further comprising:

determining an excess ammonia flow rate responsive to determining the operating mode of the SCR system is the adsorption mode;

wherein calculating the second ammonia storage surface coverage value is based, at least in part, on the determined excess ammonia flow rate.

21. The non-transitory computer-readable memory device of claim 20 storing instructions that cause the one or more processors to perform operations further comprising:

determining an excess NO_x flow rate responsive to determining the operating mode of the SCR system is the desorption mode;

wherein calculating the second ammonia storage surface coverage value is based, at least in part, on the determined excess NO_x flow rate.

22. The non-transitory computer-readable memory device of claim 20, wherein determining the ammonia compensation value is based on a desired ammonia storage surface coverage threshold of an ammonia storage control table selected based on the calculated second ammonia storage surface coverage value.